Transforming Comfort: How We Enhanced a Macungie Family Home
A Project Probono
This Macungie home had already undergone a thoughtful, well-executed retrofit that addressed major pressure and thermal boundary issues. Those improvements delivered real gains in efficiency and comfort.
Even so, like many homes with forced-air systems, small but impactful leaks remained—hidden within the ductwork—where conditioned air was still being lost.
Project Probono LLC returned to this home to complete a final layer of refinement. And by applying Aeroseal, we were able to seal residual duct leakage that couldn’t be reached during the earlier retrofit work.
This step wasn’t about correcting past work—it was about completing the system.
The result was enhanced comfort, better air delivery to living spaces, and a home that now performs as a more unified, balanced system—building on an already solid foundation.
Aeroseal Technology
Aeroseal is a proven method for sealing HVAC ductwork from the inside, targeting air leaks that are hidden behind walls, ceilings, and floor systems. These leaks often go unnoticed but can still waste energy, reduce comfort, and limit how well a heating or cooling system performs.
By sealing this residual leakage, Aeroseal helps HVAC systems deliver more of the conditioned air they already produce. Homeowners often notice immediate improved room-to-room comfort, steadier temperatures, and quieter system operation—without changing equipment.
How Aeroseal Works
The process begins by temporarily sealing supply and return registers and gently pressurizing the home’s existing HVAC distribution system. A safe, EPA-compliant, ultra-low-VOC aerosol sealant is then introduced into the homes ductwork as a fine mist.
These microscopic particles remain airborne until they encounter escaping air. At those leak points, the particles bond together, steadily sealing gaps from the inside—without coating the duct interior or restricting airflow. Areas that are already tight remain untouched.
Throughout the procedure, total system leakage levels are measured and tracked in real time using specialized diagnostic software. Pre- and post-seal results are monitored live, verified at completion, and provided as a certified report once the process is finished.
A Macungie Family Home
This Macungie family had already invested in meaningful improvements to their home. Over the prior two retrofits, the attic pressure and thermal boundaries were carefully realigned through targeted air sealing and insulation across a 2,500-square-foot home with multiple attic spaces. All previous work met DOE, state, local utility guidelines, and BPI-1200 protocols—and it performed exactly as intended.
Even with those successful upgrades in place, the family continued to notice uneven temperatures in certain areas of the home.
Project Probono LLC returned one year later to address what remained: hidden duct leakage that could not be accessed during earlier phases.
Using Aeroseal, we measured approximately 35 square inches of remaining duct leakage and successfully sealed 32 square inches of it—effectively closing the final gaps in "The Home As A System" school of thought.
Post-seal certification now shows the family's Trane furnace air-handling system operating at approximately 97.51% of its original manufacturer performance specification, closely matching factory conditions. The result was improved air delivery, enhanced comfort, and a home that now functions as a fully aligned, high-performance system.
"With leaks sealed, heating and cooling are delivered where they belong, resulting in more even temperatures, fewer hot or cold rooms, and a noticeably calmer, more comfortable home. Just as important, sealing ducts that run through wall and attic cavities prevents nasty air and dust, insulation fibers, and pollutants from being pulled into the air the family breathes."
The outcome goes beyond efficiency. Family homes that have cleaner air, steadier comfort, and a optimized system all contribute to better day-to-day comfort, improved indoor air quality, and a healthier living environment—Thats the kind of quality-of-life improvement homeowners feel immediately.
The Impact on the Homeowners
For the homeowners, the difference was immediate and meaningful. The home now feels more comfortable, more balanced, and easier to live in. Air quality improved as well, with fewer drafts and less dust being pulled in from hidden building cavities—creating a cleaner, healthier indoor environment.
Lower energy use became a natural byproduct of the improvements, helping reduce utility costs without sacrificing comfort. More importantly, the home now operates as a complete system—supporting long-term comfort, better indoor air quality, and a higher quality of life for the family.
Community, Sustainability, and What Comes Next
This Macungie project reflects how thoughtful home improvements can support both individual comfort and community well-being. By reducing energy waste and improving indoor air quality.
As more of us look for practical ways to improve comfort and reduce energy use, solutions like Aeroseal will continue to play an important role—especially as a finishing step after insulation and air-sealing work has already been done well. These improvements don’t just lower bills; they help homes last longer, perform better, and support healthier daily living.
This project is not a one-off—it’s a model. With continued, data-driven work, Project Probono aims to help more families experience the same benefits: better comfort, cleaner indoor air, lower energy waste, and a higher quality of life, one family home at a time.